KR101667516B1 - Nonwoven fabric laminate for foaming molding, method for producing nonwoven fabric laminate for foaming molding, urethane foaming molding composite using nonwoven fabric laminate, vehicle seat, and chair - Google Patents

Abstract

(A) 5% by mass to 50% by mass of a thermoplastic resin short fiber having a fiber diameter of 20 占 퐉 or more, and (B) a thermoplastic resin short fiber having a fiber diameter of 20 占 퐉 or less, wherein the reinforcing layer is 95 (C) a short polyester nonwoven fabric comprising 10% by mass to 40% by mass of a composite polyester staple fiber comprising two or more kinds of resins having different melting points, layer, and a bulk density of the nonwoven fabric in the range of ^{0.05g / cm 3 ~0.3g / cm 3} , a dense layer and the reinforcing layer is non-woven fabric laminate for foam molding which is entangled by a needle punch body.

Description

TECHNICAL FIELD [0001] The present invention relates to a nonwoven fabric laminate for foam molding, a method for producing a nonwoven fabric laminate for foam molding, a urethane foam molding compound using a nonwoven fabric laminate, a vehicle seat, and a chair, and a method for manufacturing nonwoven fabric laminate for foaming molding , URETHANE FOAMING MOLDING COMPOSITE USING NONWOVEN FABRIC LAMINATE, VEHICLE SEAT, AND CHAIR}

The present invention relates to a nonwoven fabric laminate for foam molding, which is disposed (disposed) at the bottom of a foamed molded article such as a polyurethane, a method for producing a nonwoven fabric laminate for foam molding, a composite of a urethane foamed molded article using the nonwoven fabric laminate, Sheets, and chairs.

BACKGROUND OF THE INVENTION [0002] As a cushioning material for a vehicle seat or the like, a foamed molded article such as a soft foamed polyurethane is used. In order to increase the rigidity of the molded urethane foam article and to prevent the uretane from leaching onto the back surface, a reinforcing base fabric is disposed at the bottom of the foamed molded article. As the reinforcing bubble, a combination of cold yarn and slab uretane, or a rough cloth is used. However, there is a problem that the rigidity of the molded foamed urethane product is not sufficiently improved, or prevention of leaching of the uretane to the back surface is insufficient.

A method for improving this drawback, as reinforcement for the bubble, using a basis weight of 10g / m ² ~30g / m ² of a thin dense layer and a basis weight of 40g / m ² ~100g / m ² of non-woven fabric a property writer integrated with a bulky layer A method using a high basis weight nonwoven fabric having a basis weight of 110 g / m ^{2 to} 800 g / m ² and a fiber size of 1 d to 16 d (see, for example, Japanese Patent Application Laid-Open No. 62-26193) 2-258332), a method using a meltblown nonwoven fabric having a fiber diameter of 10 탆 or less as a dense layer (see, for example, JP 2004-353153 A), a web made of fibers having a fineness of 1.1 dtex to 2.7 dtex (Dense layer) and a web having a fineness of 2.3 dtex to 8.8 dtex (bulky layer) are laminated by mechanical entangling treatment (see, for example, Japanese Patent Application Laid-Open No. 2007-146356) , And a fibrous substrate layer such as a spunbonded nonwoven fabric and at least one surface Various methods have been proposed such as a method in which laminated short fiber layers are integrated by the action of high-pressure water as a reinforcing material for foamed molded articles (see, for example, Japanese Patent Application Laid-Open No. 2005-212204).

However, any of the reinforcing bubbles for foam molding described in the above-mentioned documents is merely aimed at solving the leaching or impregnation performance at the time of foaming of the urethane foam, Is not a material that can be reduced.

2. Description of the Related Art [0002] In recent years, with the progress of design and electricalization of vehicle seats, the shape of a mold at the time of foaming urethanes becomes complicated. In order to match this shape, Is increasing. As a method for alleviating this labor, there has been proposed a molding processing method in which a nonwoven fabric sheet is placed on a mold, and heated, softened, compressed, and then transferred to the mold. A nonwoven fabric sheet in which low melting point fibers and high melting point fibers are mixed is exemplified as a reinforcing bubble used in the molding process (see, for example, Japanese Patent Application Laid-Open No. 2006-281768). Further, by using a nonwoven fabric based on a composite staple fiber composed of a blend of a high-melting-point component and a low-melting-point component of a polyester resin as an urethane reinforcement, it is possible to provide a non- (See, for example, Japanese Unexamined Patent Application Publication Nos. 2000-82548 and 2013-129950).

Further, it has been proposed to laminate dense layers in order to ensure compactness (for example, Japanese Patent Laid-Open Publication No. 2013-129950). Further, the reinforcing layer is laminated on at least one side of the dense layer, and the dense layer is formed by laminating the spunbond nonwoven fabric layer on both sides of the meltblown nonwoven fabric layer, and partially compressing the meltblown nonwoven fabric layer and the spunbond nonwoven fabric layer (See, for example, International Publication No. 2012/008169). The nonwoven fabric laminate for foam formation is excellent in resistance to delamination between layers and also suppresses powder dusting on the surface of the meltblown nonwoven fabric layer due to fiber debris when laminated (interlaced) using a needle punch. .

The nonwoven fabric obtained by the techniques of the above-mentioned Japanese Patent Application Laid-Open Nos. 2006-281768, 2012-82548 and 2013-129950 has improved followability as a mold and less labor for sewing However, at the time of following the mold, the nonwoven fabric made of short fibers is excessively elongated, so that there is a problem that extremely thin and thin portions are produced which are insufficient in denseness. In addition, the nonwoven fabric obtained by the technique of JP-A-2013-129950 has a problem that it is extremely thinned by thermal compression in the thickness direction at the time of following the mold. In any case, if urethane foam processing is carried out in the next step, the thin portion of the urethane foam is leached from the thin portion to the back surface of the urethane resin, resulting in a reduction in the reinforcing effect and an abnormal sound with the metal spring , A chair, and the like. Even in the technique of International Publication No. 2012/008169, even if elongation at the time of follow-up to a mold is maintained, the compactness is sufficiently maintained. However, when there is a fear of occurrence of thinning at the time of urethane foam molding due to compression in the thickness direction . In other words, at the time of follow-up to a mold for heating, softening and compression, a flexible material capable of sufficiently maintaining compactness even under elongation and suppressing thinning even under thermal compression in the thickness direction has not been obtained.

INDUSTRIAL APPLICABILITY The present invention has an excellent followability to a mold at the time of molding in heating, softening, and compression processing, so that even when stretched, compactness is sufficiently maintained and thinning is suppressed even in the case of thermal compression in the thickness direction. A nonwoven fabric laminated body for foam molding excellent in balance of urethane leakage preventing performance (abnormal sound preventing performance) and flexibility of a nonwoven fabric layer (a feeling of sitting when used on a chair), a urethane foam molding compound using the same, And a method for producing a nonwoven fabric laminate for foam molding.

Means for solving the above problems are as follows.

≪ 1 > a reinforcing layer laminated on at least one side of a dense layer,

Wherein the reinforcing layer contains 95% by mass to 50% by mass of thermoplastic resin short fibers having (A) 5% by mass to 50% by mass of thermoplastic resin fibers having a fiber diameter of 20 占 퐉 or more and (B) ) And the thermoplastic resin short fibers (B) are 100% by mass, and the thermoplastic resin short fibers of the above (A) or the thermoplastic resin short fibers of the above (B) (C) a composite polyester staple fiber comprising two or more kinds of resins having different melting points, wherein the content ratio of the composite polyester staple fibers (C) in the stiffening layer is 10% by mass to 40% by mass ,

Wherein the dense layer has a bulk density of the nonwoven fabric in the range of ^{0.05g / cm 3 ~0.3g / cm 3} ,

Wherein the dense layer and the reinforcing layer are entangled by needle punches.

<2> The nonwoven fabric laminate for foam molding according to <1>, wherein the thickness is 1.6 mm to 5.0 mm.

<3> The nonwoven fabric laminate for foam molding according to the item <1> or <2>, wherein the thickness after standing at 110 ° C. and 4.9 Pa for 5 minutes is 1.2 mm or more.

<4> The nonwoven fabric laminate for foam molding according to any one of <1> to <3>, wherein at least a part of the composite polyester staple fibers of (C) has a fiber diameter of 20 μm or less.

<5> The nonwoven fabric for foam molding according to any one of <1> to <4>, wherein the melting point of at least one resin forming the composite polyester staple fibers of (C) sieve.

<6> The nonwoven fabric for foam molding according to any one of the above items <1> to <5>, wherein the dense layer comprises a nonwoven fabric obtained by partially thermocompression bonding, air through processing, resin bond processing or calendaring. sieve.

<7> The nonwoven fabric laminate for foam molding according to any one of <1> to <6>, wherein the dense layer is a nonwoven fabric composed of long fibers.

<8> The thermoplastic resin composition according to the above <1>, wherein the thermoplastic resin short fibers (A) and the thermoplastic resin short fibers (B) are at least one short fiber selected from the group consisting of polyester short fibers and polyolefin short fibers The nonwoven fabric laminate for foam molding according to any one of &lt; 7 &gt; to &lt; 7 &gt;.

<9> The nonwoven fabric laminate for foam molding according to any one of <1> to <8>, wherein the thermoplastic resin short fibers of (A) and the thermoplastic resin short fibers of (B) .

<10> The nonwoven fabric laminate for foam molding according to any one of <1> to <9>, wherein the dense layer comprises a long-fiber nonwoven fabric obtained by partially thermocompression bonding.

<11> above <1> to non-woven fabric laminate for foam molding according to any one of <10> in the range of the basis weight of the dense layer ^{10g / m 2 ~35g / m 2} .

<12> nonwoven laminate for foam molding according to the item <1> to <11> any one of the permeability of the dense layer is in the range of ^{70cm 3 / cm 2 / sec~200cm 3} / cm 2 / sec.

The dense layer is formed by laminating a spunbond nonwoven fabric layer (S) composed of long fibers on both sides of a meltblown nonwoven fabric layer (M) composed of long fibers, and the meltblown nonwoven fabric layer The nonwoven fabric laminate for foam molding according to any one of the above items <1> to <12>, wherein the nonwoven fabric layer (M) and the spunbonded nonwoven fabric layer (S) are partially thermocompression bonded.

<14> differential pressure air permeability is ^{25cm 3 / cm 2 / sec~160cm 3} / cm 2 / sec of the above <1> to <13> for the nonwoven laminate of a foam molding according to any one of the body 125Pa.

<15> basis weight of 20g / m ² ~160g / m ² of the <1> to non-woven fabric laminate for <14> foam molding according to any one of the.

<16> differential pressure air permeability is ^{25cm 3 / cm 2 / sec~140cm 3} / cm 2 / sec of the above <1> to <15> for the nonwoven laminate of a foam molding according to any one of the body 125Pa.

<17> the basis weight of the reinforcing layer is in a range of 40g / m ² ~150g / m ² above <1> to <16> of the foam molding non-woven fabric laminate according to any one of the preceding body.

<18> A method for producing a nonwoven fabric laminate for foam molding according to any one of <1> to <17>

Wherein a reinforcing layer is laminated on at least one side of the dense layer and then the dense layer and the reinforcing layer are entangled by needle punches.

After the spunbond nonwoven fabric layer (S) is laminated on both sides of the meltblown nonwoven fabric layer (M), partial thermocompression bonding, air through processing, resin bond processing or calendaring is performed to form the dense layer Wherein the nonwoven fabric layer is formed on the surface of the nonwoven fabric layer.

<20> A urethane foam molded article composite comprising the foamed urethane layer provided on the outer surface of the reinforcing layer of the nonwoven fabric laminate for foam molding according to any one of <1> to <17>.

<21> The urethane foam molding according to <20>, wherein the reinforcing layer and the foamed urethane layer are formed integrally.

<22> A vehicle seat comprising the nonwoven fabric laminate for foam molding according to any one of <1> to <17>, or a composite of the urethane foam molding described in <20> or <21>.

<23> A chair comprising the nonwoven fabric laminate for foam molding according to any one of <1> to <17>, or a composite of the urethane foam molding described in <20> or <21>.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a resin composition which is excellent in followability to a mold at the time of molding in heating, softening and compression processing, and satisfactory compactness can be maintained even if elongation is applied, thinning can be suppressed even under thermal compression in the thickness direction, A nonwoven fabric laminate for foam molding excellent in balance of the effect of preventing the urethain leakage preventing performance (abnormal sound preventing performance) and the flexibility of the nonwoven fabric layer (the feeling of sitting when used on a chair), a urethane foam molding compound using the same, And a chair, and a method for producing a nonwoven fabric laminate for foam molding.

In the present specification, the numerical range indicated by using &quot; ~ &quot; indicates a range including numerical values before and after &quot; ~ &quot; as the minimum value and the maximum value, respectively.

The nonwoven fabric laminate for foam molding of the present invention comprises a reinforcing layer laminated on at least one side of a dense layer, wherein the reinforcing layer comprises (A) 5 to 50% by mass of a thermoplastic resin short fiber having a fiber diameter of 20 m or more (B) a monofilament nonwoven fabric containing 95% by mass to 50% by mass of a thermoplastic resin short fiber having a fiber diameter of 20 占 퐉 or less and a total of 100% by mass of the thermoplastic resin short fibers of the above (A) and the thermoplastic resin short fibers of , And the thermoplastic resin staple fibers of (A) or the thermoplastic resin staple fibers of (B) comprise (C) a composite polyester staple fiber comprising two or more resins having different melting points, the composite polyester content of the staple fibers of the (C) of the reinforcing layer is 10 mass% to 40 mass%, the dense layer has a bulk density of the nonwoven fabric in the range of 0.05g / cm ³ ~0.3g / cm ^3, and , The dense layer and the reinforcing layer It is entangled by.

Foam molding for a nonwoven fabric laminated product of the present invention includes a dense layer of a bulk density in the range of 0.05g / cm ³ ~0.3g / cm ³ and non-woven fabric, a non-woven fabric of the reinforcing layer to a specific short fiber containing a specific amount of needle punching It is possible to obtain excellent followability to a mold at the time of molding by heating, softening and compression processing, to maintain sufficient compactness even if elongated, and to suppress thinning even when subjected to thermal compression in the thickness direction , The reinforcing effect can be obtained even after the trimming. Further, with the above-described constitution, it is possible to process the molded article into a complicated shape, which is excellent in flexibility even after molding, and can be processed in a shape suitable for a mold of a foamed molded article, And is excellent in a feeling of sitting when used in a chair or the like. In addition, with the above-described structure, sufficient compactness can be maintained on the entire surface. Therefore, when foam molding such as urethane resin is carried out on the nonwoven fabric laminate for foam molding of the present invention, permeation (exudation or leaching) of the resin composition for foam molding including uretane can be suitably prevented.

In the urethane foamed molded article composite of the present invention, a foamed urethane layer is provided on the outer surface of the reinforcing layer of the nonwoven fabric laminate for foam molding. It is preferable that the reinforcing layer and the foamed urethane layer are integrally formed. When the urethane foam molded article composite is produced by using the nonwoven fabric laminate for foam molding of the present invention, the laminate is suitably followed by a mold having a desired shape, and the uretane leaching is suppressed, Layer can be suitably formed.

The urethane foamed molded article composite of the present invention suppresses the leakage of urethane into the side of the nonwoven fabric laminated body which becomes bubbles. Therefore, when used in the production of automobile seats, for example, an abnormality caused by friction between metal parts and foamed urethane The sound can be effectively prevented and the flexibility of the nonwoven fabric is sufficiently maintained, so that it is possible to improve the ride feeling (seating feeling).

Further, in the method for producing a nonwoven fabric laminate for foam molding of the present invention, after the reinforcing layer is laminated on at least one surface of the dense layer, the dense layer and the reinforcing layer are entangled by a needle punch. According to the production process of the present invention, a nonwoven fabric laminate for foam molding having the above excellent properties can be suitably produced.

Hereinafter, the present invention will be described in detail.

&Lt; Nonwoven fabric laminate for foam molding &gt;

The nonwoven fabric laminate for foam molding of the present invention has a reinforcing layer on at least one side of the dense layer. The reinforcing layer according to the present invention comprises (A) 95% by mass to 50% by mass of a thermoplastic resin short fiber having 5% by mass to 50% by mass of thermoplastic resin fibers having a fiber diameter of 20 占 퐉 or more and (B) Wherein the thermoplastic resin short fibers (A) and the thermoplastic resin short fibers (B) are 100% by mass in total of the thermoplastic resin short fibers (A) and the thermoplastic resin short fibers (B) The fiber includes (C) a composite polyester staple fiber comprising two or more kinds of resins having different melting points, wherein the content ratio of the composite polyester staple fibers of (C) in the stiffening layer is 10 mass% to 40 Mass%. In addition, the dense layer according to the invention, the bulk density is a nonwoven fabric in the range of ^{0.05g / cm 3 ~0.3g / cm 3} , preferably consisting of a long-fiber.

In the present invention, &quot; short fibers &quot; means fibers having an average fiber length of 200 mm or less. "Long fiber" refers to "continuous filament" commonly used in the art, such as nonwoven handbook (INDA USA Nonwoven Fabric Association, Nonwoven Fabric Information, 1996).

The fiber diameter refers to the value obtained by the following method.

Ten test specimens of 10 mm x 10 mm are taken from the obtained nonwoven fabric, and the diameters of the fibers are read in μm to the first decimal place using an ECLIPSE E400 microscope manufactured by Nikon at a magnification of 20 times. 1 Diameter of arbitrary 30 points is measured for each test piece, and an average value is obtained. The sample piece was taken from the obtained nonwoven fabric and observed with a scanning electron microscope at a magnification of 500 or 1000, and the fiber diameter (μm) of 30 constituent fibers was measured. And an average value is obtained.

The term "thermoplastic resin short fibers (A) having a fiber diameter of 20 μm or more" is referred to as "(B)" and "thermoplastic resin short fibers having a fiber diameter of 20 μm or less" , And "(C) a composite polyester staple fiber comprising two or more kinds of resins having different melting points" are sometimes referred to as "composite polyester staple fibers of (C)".

(Reinforcing layer)

The reinforcing layer constituting the nonwoven fabric laminate for foam molding of the present invention comprises (A) 5% by mass to 50% by mass of thermoplastic resin short fibers having a fiber diameter of 20 占 퐉 or more, and 95% by mass of the thermoplastic resin short fibers having a fiber diameter of 20 占 퐉 or less (A) and the thermoplastic resin short fibers (B) in a total amount of 100% by mass, wherein the thermoplastic resin short fibers of (A) and the thermoplastic resin short fibers of The thermoplastic resin staple fiber of (B) includes (C) a composite polyester staple fiber including two or more kinds of resins having different melting points, and the composite polyester staple fibers of (C) Is 10% by mass to 40% by mass.

(C) a composite polyester staple fiber comprising two or more kinds of resins having different melting points is used in consideration of the shape retentivity of the mold after molding into a mold. As the resin for forming the composite polyester staple fibers of (C), polyethylene terephthalate is preferably contained, and further polyethylene may be contained. When the composite polyester staple fiber of (C) comprises polyethylene terephthalate and polyethylene, it is preferable that the polyethylene has a melting point lower than that of polyethylene terephthalate.

The composite polyester staple fiber (C) in the present invention is a composite fiber composed of two or more kinds of polyesters having different melting points, a resin other than one or more kinds of polyester and polyester, And a composite fiber formed by including these different resins may be used. Specifically, there may be mentioned core-sheath composite fibers of a high melting point polyethylene terephthalate (PET) resin and a low melting point PET resin, and core-sheath composite fibers of a high melting point PET resin and a low melting point polyethylene (PE) resin.

The melting point of the at least one resin forming the composite polyester staple fibers of the polyester (C) is preferably 110 ° C to 190 ° C, more preferably 110 ° C to 140 ° C, more preferably 110 ° C to 120 ° C desirable. On the other hand, it is preferable that the resin having the melting point of 110 ° C to 190 ° C is a resin having the lowest melting point (low melting point resin) among the resins forming the composite polyester staple fiber.

(C) is preferably 10% by mass to 50% by mass, more preferably 20% by mass to 40% by mass, still more preferably 25% by mass to 35% by mass More preferably, it is in mass%.

The content ratio of the composite polyester staple fibers in (C) in the reinforcing layer determines the shape retentivity after molding into a mold, the flexibility and thickness of the nonwoven fabric. The reinforcing layer according to the present invention comprises 10% by mass to 40% by mass of the composite polyester short fibers of (C). If the content of the composite polyester staple fibers in the polyester (C) is less than 10% by mass, the flexibility and the thickness of the nonwoven fabric after the patterning are sufficient, but the adhesion between the fibers is insufficient and the shape- If the content of the composite polyester staple fibers in the polyester (C) exceeds 40% by mass, the shape-retaining property as a mold is sufficient, but the adhesion between the fibers becomes excessive, and the nonwoven fabric becomes hard and the flexibility is impaired. In addition, the portion subjected to compression in the thickness direction at the time of heating, softening, and compression processing becomes extremely thin, and this portion is undesirable because it becomes a cause of uretane leakage at the time of subsequent urethane foam processing. More preferably, the reinforcing layer comprises 20% by mass to 35% by mass of the composite polyester staple fibers of (C).

(C) is not particularly limited, and it is possible to use a fiber having a diameter of 10 m to 30 m, and it is possible to effectively increase the bonding point between the fibers during heating, softening and compression, It is preferable that the fiber diameter is 20 μm or less, more preferably 18 μm or less, even more preferably 17 μm or less, and particularly preferably 15 μm or less in at least a part of the composite polyester staple fibers of (C) .

On the other hand, when the composite polyester staple fibers of (C) include those having a fiber diameter of 20 탆 or less, the total fiber diameter of the composite polyester staple fibers of (C) may be 20 탆 or less, Or may be in the form of mixed fibers, which further comprise composite polyester short fibers. (C) is not particularly limited, and the ratio of the thermoplastic resin (A) and the thermoplastic resin (B) to the total mass of the composite polyester staple fibers of the thermoplastic resin (A) It is possible to appropriately adjust the content of the resin short fibers insofar as they satisfy the range of the present invention.

The reinforcing layer according to the present invention comprises (A) a thermoplastic resin short fiber having a fiber diameter of 20 μm or more and (B) a thermoplastic resin short fiber having a fiber diameter of 20 μm or less, wherein the thermoplastic resin short fiber of (A) The total amount of the thermoplastic resin short fibers is 100% by mass.

The content of the thermoplastic resin short fibers in the reinforcing layer (A) is 5% by mass to 50% by mass. The ratio of the thermoplastic resin short fibers in the thermoplastic resin (A) determines the thickness of the nonwoven fabric after the template is transferred. By setting the content ratio of the thermoplastic resin short fibers in the reinforcing layer within the above range, it becomes easy to secure a sufficient thickness and to suppress thinning even when subjected to thermal compression in the thickness direction. When the content of the thermoplastic resin short fibers in the reinforcing layer (A) exceeds 50% by mass, the thickness of the nonwoven fabric is sufficiently ensured. However, when the voids of the reinforcing layer become excessively large and the strength is damaged or uretane is foamed on the reinforcing layer, And the urethane reinforcement effect is deteriorated. When the content of the thermoplastic resin short fibers in the reinforcing layer (A) is less than 5% by mass, the strength as a reinforcing layer tends to be excellent. However, when the thickness of the nonwoven fabric becomes too thin and flexibility is poor or when urethane is foamed on the reinforcing layer, And it is not preferable because it becomes easy to occur. In the reinforcing layer, the content of the thermoplastic resin short fibers in (A) is more preferably 10% by mass to 45% by mass, and still more preferably 15% by mass to 40% by mass.

The fiber diameter of the thermoplastic resin short fibers of (A) is not particularly limited as long as it is larger than 20 m, preferably not smaller than 23 m, and more preferably not smaller than 25 m. The fiber diameter of the thermoplastic resin staple fibers of (A) is preferably 45 μm or less in consideration of the flexibility of the resultant nonwoven fabric and the compatibility of the reinforcing layer with other fibers. The upper limit of the fiber diameter of the thermoplastic resin short fibers of (A) is more preferably 39 m.

On the other hand, the thermoplastic resin staple fibers of (A) may contain, as a part thereof, the composite polyester staple fibers of the above-mentioned (C).

The content of the thermoplastic resin short fibers in the reinforcing layer (B) is 50% by mass to 95% by mass, preferably 50% by mass to 70% by mass, and more preferably 50% by mass to 65% by mass. As a result of satisfying the above constitution ratio, the staple fibers having a small fiber diameter are appropriately included, and the pore balance of the reinforcing layer becomes optimum. As a result, the resultant nonwoven fabric becomes soft and uretane leakage in the case of urethane foam can be prevented. In addition, an appropriate extensibility of the nonwoven fabric can be obtained. As a result, the effect of improving the followability of the nonwoven fabric to the mold during heating, softening and compression can be obtained.

The fiber diameter of the thermoplastic resin short fibers of the thermoplastic resin (B) is not particularly limited as long as it is 20 μm or less, preferably 18 μm or less, more preferably 17 μm or less, and further preferably 15 μm or less. The fiber diameter of the thermoplastic resin short fibers of the thermoplastic resin (B) is preferably about 10 탆, more preferably about 12 탆, in consideration of the interfacial properties of the reinforcing layer with other fibers.

On the other hand, the thermoplastic resin staple fibers of (B) preferably include the above-mentioned (C) composite polyester staple fibers.

The thermoplastic resin short fibers of the thermoplastic resin (A) and the thermoplastic resin short fibers of (B) are not particularly limited as long as they are thermoplastic resins capable of forming a nonwoven fabric, and various known thermoplastic resins can be used. The thermoplastic resin short fibers are preferably each independently a polyolefin short fiber or a polyester short fiber formed from a propylene polymer or the like. The thermoplastic resin preferably has thermal stability during heating, softening and compression, From the viewpoint of having sufficient rigidity, it is more preferable to be a polyester staple fiber.

The thermoplastic resin short fibers of (A) and the thermoplastic resin short fibers of (B) other than the composite polyester short fibers of (C) are preferably high melting point polyester short fibers having a melting point exceeding 190 캜 . When the melting point exceeds 190 占 폚, the fibers are prevented from being melted by heat received during heating, softening and compression. When the fibers are melted, the nonwoven fabric becomes hard or the portion that has been compressed in the thickness direction becomes extremely thin, and this portion is undesirable because it becomes a cause of uretane leakage at the time of subsequent urethane foam processing.

(C), the thermoplastic resin short fibers (A), and the thermoplastic resin short fibers (B) each have an average fiber length of usually 200 mm or less, preferably 10 mm to 100 mm, 30 mm to 90 mm.

(C) is not limited to any other form as long as it comprises two or more resins having different melting points, and may be a mixed fiber obtained by mixing two or more kinds of fibers having different shapes .

The thermoplastic resin short fibers of (A) and the thermoplastic resin short fibers of (B) may also be mixed fibers composed of two or more different thermoplastic resin fibers mixed together, Or mixed fibers obtained by mixing two or more kinds of fibers.

(C), the thermoplastic resin short fibers (A), and the thermoplastic resin short fibers (B) may be composite fibers of side-by-side type or core-sheath type. The cross-sectional shape of the staple fibers may be an annular shape, a hollow shape such as a hollow shape, a V shape, a cruciform shape, a T shape, or the like. Further, it may be pre-crimped or may be fiber of potential crimp.

A known method may be used for obtaining the nonwoven fabric from the short fibers, and preferably, a method of mechanically bonding by fusing with a needle punch or fusion bonding by heat treatment can be employed. In order to efficiently perform lamination with the subsequent dense layer, it is preferable to make the reinforcing layer nonwoven with a needle punch.

The bulk density of the reinforcing layer is preferably from 0.01 g / cm ^{3 to} 0.1 g / cm ³ , and more preferably from 0.02 g / cm ^{3 to} 0.09 g / cm ³ , more preferably in the range of ^{0.03g / cm 3 ~0.08g / cm 3} .

The basis weight of the reinforcing layer is usually 40g / m ² and ~180g / m ^2, preferably ^{40g / m 2 ~160g / m 2} , more preferably from ^{40g / m 2 ~150g / m 2} , more preferably from 45g / m ² ~130g / m ^2, and particularly preferably in the range of ^{50g / m 2 ~100g / m 2} .

The reinforcing layer may be a single layer or two or more layers. When the reinforcing layer is a laminate of two or more layers, it may be composed of the same type of nonwoven fabric or may be composed of different nonwoven fabrics. When the reinforcing layer is composed of two or more nonwoven fabrics, they may be laminated and bonded in advance by known methods, or may be formed by laminating the reinforcing layers collectively at the time of forming the nonwoven fabric laminate for foam molding.

(PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), and polylactic acid (PLA) as the polyester constituting the composite polyester fiber of the polyester (C). Specific examples of the polyester include polyethylene terephthalate , And copolymers thereof, and combinations thereof, and the like. Among them, polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and polybutylene terephthalate (PBT) are more preferable in view of molding processability. In the case where the thermoplastic resin short fibers of (A) and the thermoplastic resin short fibers of (B) are composed of polyester, the above-mentioned polyesters can be exemplified as the corresponding polyesters.

(C), the thermoplastic resin short fibers of (A) and the thermoplastic resin short fibers of (B) may contain additives such as antioxidants, weather stabilizers Various known additives such as a light stabilizer, a light stabilizer, an antiblocking agent, a lubricant, a nucleating agent, a pigment, a softener, a hydrophilic agent, a preparation, a water repellent agent, a filler, an antibacterial agent, a flame retardant agent, a deodorant and a sorbent material may be added. These additives may be added to the surface of the fibers by means such as spraying after the formation of the nonwoven fabric.

The reinforcing layer according to the present invention may be provided only on one side of the dense layer or on both sides of the dense layer.

(Dense layer)

Dense layer constituting the nonwoven fabric laminate for the foam molding of the present invention, the bulk density is a nonwoven fabric in the range of ^{0.05g / cm 3 ~0.3g / cm 3} , preferably a nonwoven fabric composed of long fibers. In the present invention, in the case of receiving heat of about 180 캜 at the time of heating, softening, and compression molding, from the viewpoint of heat resistance, the fibers constituting the dense layer include polyolefin fibers formed of a propylene- Based fiber is preferable. From the viewpoint of heat resistance stability, polyester-based fibers are more preferable. However, from the viewpoints of flexibility, productivity and the like, polyolefin-based fibers formed of a propylene-based polymer or the like are more preferable when heat received at the time of molding is up to about 110 캜. Further, it may be formed of a polymer other than the polyolefin-based fiber and the polyester-based polymer.

In the dense layer, the polymer forming the fiber is not particularly limited as long as it is a thermoplastic resin capable of forming a nonwoven fabric, and various known thermoplastic resins can be used. Specific examples of the polymer include polypropylene (propylene homopolymer), polypropylene random copolymer, poly 1-butene, poly 4-methyl-1-pentene, ethylene / propylene random copolymer, ethylene / 1-butene random copolymer, (Nylon-6, nylon-66, polymethylacrylamide, and the like) such as polypropylene and propylene-1-butene random copolymer; polyolefins such as polyethylene terephthalate, polyethylene terephthalate and polyethylene naphthalate; , Polyvinyl chloride, polyimide, ethylene / vinyl acetate copolymer, ethylene / vinyl acetate / vinyl alcohol copolymer, ethylene / (meth) acrylic acid copolymer, ethylene-acrylic acid ester-carbon monoxide copolymer, polyacrylonitrile, poly A carbonate, a polystyrene, an ionomer, or a mixture thereof.

Among these thermoplastic resins, polyolefins are preferable, propylene polymers are more preferable, and polypropylene or polypropylene random copolymers are more preferable from the viewpoints of radiation stability at molding, nonwoven fabric workability, air permeability, flexibility, light weight and heat resistance Do.

Preferable examples of the propylene-based polymer include homopolymers of propylene having a melting point (Tm) in the range of 125 占 폚 or higher, preferably 130 占 폚 to 165 占 폚 or propylene homopolymers and copolymers of propylene and ethylene, 1-butene, (Excluding 3 carbon atoms), preferably 2 to 8 carbon atoms (excluding 3 carbon atoms), such as 1-octene, 4-methyl- Olefin. &Lt; / RTI &gt;

The melt flow rate (MFR: ASTM D-1238, 230 캜, load 2160 g) of the propylene-based polymer is not particularly limited so long as it can melt-spin. The melt flow rate of the propylene polymer is usually 10 g / 10 min to 3000 g / 10 min, preferably 50 g / 10 min to 2000 g / 10 min, more preferably 100 g / 10 min 10 min to 500 g / 10 min, preferably 5 g / 10 min to 200 g / 10 min, and more preferably 5 g / 10 min to 1000 g / 10 min when used for the spunbond nonwoven fabric and the reinforcing layer. 10 g / 10 min to 100 g / 10 min.

The thermoplastic resin according to the present invention may contain additives such as an antioxidant, a weather stabilizer, a light stabilizer, an antiblocking agent, a lubricant, a nucleating agent, a pigment, a softener, a hydrophilic agent, A flame retardant, a deodorant, a sorbent and the like may be added.

The bulk density of the dense layer is in the range of ^{0.05g / cm 3 ~0.3g / cm 3} , preferably ^{0.05g / cm 3 ~0.15g / cm 3} . When the bulk density of the dense layer is within the above range, it is preferable that the dense nature of the fiber can be maintained even after entanglement and a good effect is exhibited on the uretane leaching.

The basis weight of the dense layer, is usually ^{10g / m 2 ~60g / m 2} , preferably in the range of ^{10g / m 2 ~35g / m 2} , more preferably from ^{10g / m 2 ~25g / m 2} . When the basis weight of the dense layer is 10 g / m &lt; ² &gt; or more, the strength is improved and the handling property is excellent even after lamination with the reinforcing layer. When the basis weight is 60 g / m ² or less, not only the effect of lighter weight can be obtained but also the elongation tends to occur at the time of follow-up to the mold for heating, softening and compression.

Air permeability of the dense layer is preferably ^{50cm 3 / cm 2 / sec~300cm 3} / cm 2 / sec, and more preferably ^{50cm 3 / cm 2 / sec~250cm 3} / cm 2 / sec, more preferably from 70cm ³ / cm ² / sec to ²⁰⁰ cm ³ / cm ² / sec. When the air permeability of the dense layer is in the above range, compactness after lamination with the reinforcing layer is maintained, and leakage prevention of urethane is good. As a result, since the foamed urethane layer can be densely formed, it is effective for improving the rigidity of the foam.

It is preferable that the dense layer includes a nonwoven fabric obtained by partially thermocompression bonding, air through processing, resin bond processing or calendaring. More preferably, the dense layer is partially thermocompression-bonded and embossed. In the present invention, &quot; partially &quot; means an area ratio of 5% to 30%, preferably 5% to 20%.

The dense layer may further include nonwoven fabrics not subjected to partial thermocompression bonding, air through processing, resin bond processing or calendaring, or may include a plurality of nonwoven fabrics subjected to these processes.

The dense layer preferably satisfies the bulk density, the basis weight, and the air permeability, and various known nonwoven fabrics can be used. For example, spunbond nonwoven fabric, meltblown nonwoven fabric, wet nonwoven fabric, dry nonwoven fabric, dry pulp Nonwoven fabrics, flash-spun nonwoven fabrics, carded nonwoven fabrics, and the like. Among these nonwoven fabrics, the dense layer is formed on at least one surface of a spunbonded nonwoven fabric or a meltblown nonwoven fabric layer (M) in such a manner that the spunbonded nonwoven fabric layer (S ) And a spunbond meltblown nonwoven fabric (SM (S)) in which the meltblown nonwoven fabric layer and the spunbonded nonwoven fabric layer are partially thermally bonded. The SMS nonwoven fabric in which the spunbonded nonwoven fabric layer (S) is partially thermally pressed and laminated on both sides of the meltblown nonwoven fabric layer (M) is more preferable in view of attaining appropriate strength and air permeability after realizing the weight saving Do.

The dense layer may be composed of a single piece of SMS nonwoven fabric subjected to partial thermocompression bonding, air through processing, resin bond processing, or calender processing, or may be a laminate including a plurality of SMS nonwoven fabrics subjected to these treatments.

The meltblown nonwoven fabric layer (M) suitable for use in the present invention is a nonwoven fabric layer formed of the above thermoplastic resin. The nonwoven fabric layer usually has a fiber diameter of 0.1 m to ⁵ m, preferably 0.5 m to ³ m, in the range of 5g / m ^2, preferably ^{1g / m 2 ~3g / m 2} .

When the fiber diameter and basis weight of the meltblown nonwoven fabric layer (M) are in the above range, it is possible to effectively prevent the urethane from leaching out when used as a dense layer, and even when the dense layer and the base layer are bonded with a needle punch , The fibers of the meltblown nonwoven fabric layer (M) are less likely to be cut off by the needles, and furthermore, the resulting nonwoven fabric laminate for foam molding can be reduced in weight.

The spunbond nonwoven layer (S) suitable according to the present invention is a nonwoven fabric layer made of the thermoplastic resin, generally, fibers wonder 10μm~40μm, preferably 10μm~20μm, a basis weight of ^{5g / m 2 ~25g / m 2} , preferably in the range of ^{5g / m 2 ~10g / m 2} .

When the fiber diameter and the basis weight of the spunbonded nonwoven fabric layer (S) are in the above ranges, the fibers of the dense layer and the reinforcing layer can be strongly entangled with each other when the dense layer and the reinforcing layer are joined by needle punching, The weight and strength of the nonwoven fabric laminate can be made compatible, and the leakage of uretane can be effectively prevented.

The spunbond-meltblown nonwoven fabric (SM (S)) is produced by using various known meltblown nonwoven fabrics and spunbond nonwoven fabrics.

Specifically, for example, the thermoplastic resin is radiated from a spinneret in advance, the filament is cooled by a cooling fluid or the like, and a tension is applied to the filament by stretched air to obtain a predetermined fineness. And the spunbond nonwoven fabric layer S is obtained by melt-extruding the thermoplastic resin on the spunbonded nonwoven fabric layer S, and the fibers spun from the melt blown spinneret are extruded at a high temperature high speed And a spunbond nonwoven fabric layer (M) is formed on the meltblown nonwoven fabric layer (M) by spinning as a superfine fiber by a gas of a meltblown nonwoven fabric layer (M) (SMS) can be manufactured by partially laminating the laminate (S) and then thermocompression.

The dense layer (in particular, the meltblown nonwoven fabric layer (M) and the spunbond nonwoven fabric layer (S)) is subjected to partial thermocompression bonding, air through processing, resin bond processing or calendaring. May be adopted. In particular, when the dense layer is partially thermally bonded by embossing or the like, the bulk density of the resulting dense layer is easily adjusted to the above range, and the strength and rigidity of the dense layer are improved, It is easy to install in a mold and work speed is improved. It is also preferable from the viewpoint that the resin liquid for foam molding including urethane can be prevented from passing therethrough.

In the case of thermal fusion bonding by thermal embossing, the embossing area ratio is usually in the range of 5% to 30%, preferably 5% to 20%. The engraved shape is exemplified by a circle, an ellipse, a circle, a square, a rhombus, a rectangle, a square, a quilt, a lattice,

Since the fiber forming the spunbonded nonwoven fabric layer S generally has a larger fiber diameter than the fibers forming the meltblown nonwoven fabric layer M, the spunbonded nonwoven fabric layer S in the dense layer according to the present invention (Both surfaces) of the meltblown nonwoven fabric layer (M). With this configuration, the spunbonded nonwoven fabric layer (S) fulfills the role of reinforcing the meltblown nonwoven fabric layer (M) more effectively.

The dense layer may be composed of one nonwoven fabric or two or more layers of nonwoven fabric. When the nonwoven fabric is composed of two or more nonwoven fabrics, the nonwoven fabric may be composed of the same kind of nonwoven fabric or may be composed of different nonwoven fabrics. In the case where the dense layer is composed of two or more nonwoven fabrics, they may be laminated and bonded together by a known method in advance, or may be formed by laminating a dense layer collectively at the time of forming the nonwoven fabric laminate for foam molding do.

(Nonwoven fabric laminate for foam molding)

The nonwoven fabric laminate for foam molding of the present invention has a reinforcing layer laminated on at least one side of a dense layer, and the dense layer and the reinforcing layer are entangled by a needle punch.

The nonwoven fabric laminate for foam molding of the present invention is formed by laminating a reinforcing layer on at least one surface, preferably both surfaces, of a dense layer. The dense layer usually has a higher bulk density than the reinforcing layer. When the reinforcing layer is laminated only on one side, an expanded molded article such as a foamed urethane layer is formed on the side where the reinforcing layer is laminated.

In order to ensure elongation as a nonwoven fabric laminate at the time of molding into a mold, thickness and flexibility after finishing, it is desirable that the reinforcing layer be the main body of the nonwoven fabric laminate, and the dense layer should be made as small as necessary. It is preferable that the basis weight and the composition of the base material are within the above-mentioned range.

The basis weight as a non-woven fabric laminate for foam molding is preferably ^{20g / m 2 ~160g / m 2} , more preferably from ^{40g / m 2 ~140g / m 2} , more preferably from 50g / m ² ~120g / m ² Lt; / RTI &gt; If the basis weight of the nonwoven fabric laminate for foam molding is 20 g / m ² or more, the strength becomes sufficient and the handling property is excellent, and the thickness becomes sufficient, and uretane leakage tends to be suppressed. When the basis weight of the non-woven fabric laminate for foam molding is 160 g / m ² or less, the weight reduction is excellent and the stretching at the time of trimming to a mold becomes easy.

INDUSTRIAL APPLICABILITY The nonwoven fabric laminate for foam molding of the present invention can be applied to a foamed nonwoven fabric laminate for foam molding, which is composed of only a reinforcing layer, in order to secure a thickness from the viewpoint of ensuring prevention of urethane leakage and flexibility, The strength as a laminated body is maintained at a satisfactory level. The thickness of the nonwoven fabric laminate for foam molding of the present invention is preferably 1.6 mm to 5.0 mm, more preferably 2.0 mm to 4.5 mm. When the thickness of the nonwoven fabric laminate for foam molding is 1.6 mm or more, the urethane leakage can be further suppressed, and the flexibility of the nonwoven fabric layer is excellent. When the thickness of the nonwoven fabric laminate for foam molding is 5.0 mm or less, the following property to a mold tends to be excellent.

In the nonwoven fabric laminate for foamed molding according to the present invention, the thickness after standing at 110 DEG C and 4.9 Pa for 5 minutes can be 1.2 mm or more. When the thickness is 1.2 mm or more after being left at 110 DEG C and 4.9 Pa for 5 minutes, thinning is suppressed even when subjected to thermal compression in the thickness direction, and the leaching at the time of urethane foam processing is advantageously suppressed. More preferably not less than 1.3 mm, further preferably not less than 1.4 mm, and particularly preferably not less than 1.5 mm.

It is preferable that the nonwoven fabric laminate for foam molding of the present invention has sufficient denseness so that the foaming resin such as urethane is not spilled at the stage of molding the foamed molded article. On the other hand, it is preferable that the nonwoven fabric laminate maintains air permeability Do. Non-woven laminate body for foam molding, the air permeability with a pressure difference of ^{125Pa, 20cm 3 / cm 2 /} sec~160cm is preferred, and a ^{3 / cm 2 / sec 25cm 3} / cm 2 / sec~160cm 3 / cm 2 / sec, and more ^{preferably, 25cm 3 / cm 2 / sec~140cm} 3 / cm 2 / sec , and it is more ^{preferable, 30cm 3 / cm 2 / sec~125cm} 3 / cm 2 / sec is particularly preferred, and 30cm ³ / cm ² / sec to 115 cm ³ / cm ² / sec. When the air permeability of the nonwoven fabric laminate for foam molding is in the above range, the foaming resin such as uretene can be prevented from leaching out more effectively, and the gas generated by the foaming molding can be suitably discharged. As a result, since the foam layer can be densely formed, it is effective for improving the rigidity of the foam.

The tensile strength (N / 50 mm) of the nonwoven fabric laminate for foam molding of the present invention is preferably 30 N or more, and more preferably 40 N or more, because it is excellent in handling property.

Such a nonwoven fabric laminate for foam molding of the present invention may be laminated with another base layer in a range that does not impair the effect of the present invention and used for foam molding.

Specific examples of the base layer laminated with the nonwoven fabric laminate of the present invention include a woven fabric, a woven fabric, a nonwoven fabric, a film, a paper product, and the like. Examples of the method of laminating (bonding) the nonwoven fabric laminate of the present invention and other layers include thermal fusion bonding methods such as heat embossing and ultrasonic bonding, mechanical interlocking methods such as needle punches and water jets, hot melt adhesives, A method using an adhesive of an adhesive, an extrusion laminate, and the like, may be employed.

&Lt; Process for producing nonwoven fabric laminate for foam molding &gt;

In the method for producing a nonwoven fabric laminate for foam molding of the present invention, after a reinforcing layer is laminated on at least one side of a dense layer, the dense layer and the reinforcing layer are entangled by a needle punch. The nonwoven fabric laminate for foam molding can be produced by various known methods, for example, a heat fusion method such as heat embossing or ultrasonic fusing, a mechanical interlocking method such as needle punch or water jet, a hot melt adhesive, A method in which a dense layer and a reinforcing layer are laminated by means of an adhesive such as a phosphorus-based adhesive, an extrusion laminate, and the like. The bonding of the dense layer and the reinforcing layer is performed by a heat fusion method in which the bonding is performed mechanically by a needle punch or by heat treatment Can be adopted. Above all, in the present invention, a layered product obtained by joining together a dense layer and a reinforcing layer is integrally formed by entanglement treatment using a needle punch. With this configuration, the dense layer and the reinforcing layer are bonded by mechanical interlocking without bias. In addition, the needle punch can maintain the best balance of the thickness and the compactness as a laminate. Therefore, the nonwoven fabric laminate for foam molding of the present invention can be produced without causing unevenness in the thickness following stretching, without interfering with the step of following the mold for producing the expanded molded article in a three-dimensional manner, It is possible to maintain a good denseness and flexibility on the whole surface and to maintain the proper air permeability in the resultant nonwoven fabric laminate for foam molding so that gas generated when uretene or the like is foam molded can be passed therethrough, It is possible to prevent leakage by controlling the impregnation of the liquid.

Further, in order to reduce yarn breakage at the time of needle punching or to reduce abnormal noise between the foam and the metal part when the needle punch is laminated (entangled), the nonwoven fabric An oil agent such as a plasticizer or a slip agent may be introduced or applied.

In the nonwoven fabric laminate for foam molding of the present invention, for example, when a dense layer obtained by partially laminating the spunbond nonwoven fabric layer (S) on both surfaces of a meltblown nonwoven fabric layer (M) by thermocompression bonding is used, Even when the dense layer and the reinforcing layer are joined by the needle punching method, the fibers forming the spunbonded nonwoven fabric layer S and the fibers forming the reinforcing layer are not broken and the entanglement is increased. As a result, even if the bonding strength between the dense layer and the reinforcing layer is strengthened and the fibers of the meltblown nonwoven fabric layer (M) are cut with needles, the cutting chips may come to the surface of the nonwoven fabric laminate for foam molding There is no.

In the nonwoven fabric laminate for foam molding of the present invention, the dense layer and the reinforcing layer are bonded by the needle punching method as described above, and the dense layer exhibits the effect as the base layer. Therefore, the constitution of the reinforcing layer can be freely It is possible to adjust. The effect of the dense layer as the base layer is not only the effect of maintaining the strength as a laminate but also the effect of retaining the fibers of the stiffening layer of the stiffening layer (falling-off prevention) or the effect of dimensionally stabilizing the laminate at the time of following heating, appear. It is possible to prevent an appropriate strength, moderate elongation, and excessive heat shrinkage as compared with the case of a single reinforcing layer (short fiber).

The nonwoven fabric laminate for foam molding of the present invention may be subjected to secondary processing such as gear processing, printing, coating, laminating, heat treatment, shaping, water repellent treatment, hydrophilic treatment, etc. within the range not impairing the object of the present invention do.

The nonwoven fabric laminate for foam molding of the present invention can be applied to any foamed molded article, and can be applied to a foamed molded article made of, for example, uretane to provide good rigidity, prevention of abnormal sound, and ride comfort. For example, it can be applied to molding foamed molded articles for various purposes such as seat for vehicle seat such as car seat, furniture, office chair, bed, and the like.

<Urethane foam molding compound>

The urethane foamed molded article composite of the present invention is formed by providing a foamed urethane layer on the outer surface of the reinforcing layer of the nonwoven fabric laminate for foam molding of the present invention described above. It is preferable that the urethane foamed molded article composite of the present invention is formed by integrally forming the reinforcing layer and the foamed urethane layer of the nonwoven fabric laminate for foam molding of the present invention described above. The foamed urethane layer is usually produced by foaming a polyurethane in a mold of a desired shape. The urethane foamed molded article composite of the present invention can be produced by, for example, arranging and following the above-mentioned nonwoven fabric laminate for foam molding of the present invention on the upper or lower part of a mold such as a mold, And then subjected to foam molding.

In the present invention, since the nonwoven fabric laminate for foam molding has good moldability and satisfactory denseness and flexibility at the whole surface can be achieved even after following the mold, the uretane leaching can be suppressed, It is possible to suppress the exudation of the foam to the surface and to produce a urethane foam molded article composite which is integrated with the molded article.

The urethane foamed molded article composite of the present invention is suitable for various uses such as automobile seats such as automobiles, trams, airplanes, and rides, furniture such as chairs and beds, toys, building materials and the like using urethane foam molding Can be applied.

INDUSTRIAL APPLICABILITY By using the nonwoven fabric laminate for foam molding of the present invention, the urethane foamed molded article composite of the present invention can be easily produced by foam molding using a reinforcing material in a mold without complicated steps such as cutting or sewing of a reinforcing material In addition, when used in combination with a metal part or the like such as a vehicle seat application, it is possible to effectively prevent an abnormal sound caused by friction between the metal part and the foamed urethane, and to realize a good ride feeling And the like.

The urethane foam molded article composite of the present invention can be applied to any foamed molded article and can be applied to a foamed molded article formed, for example, by urethane or the like to give good rigidity, prevention of abnormal sound, and ride comfort . For example, it can be applied to molding foamed molded articles for various purposes such as seat for vehicle seat such as car seat, furniture, office chair, bed, and the like.

Example

Hereinafter, the present invention will be described more specifically based on examples, but the present invention is not limited to these examples.

The physical properties and the like in Examples and Comparative Examples were measured by the following methods.

(1) Basis weight (g / m ² )

Ten points were sampled from the nonwoven fabric in a size of 100 mm in the machine direction (MD) × 100 mm in the transverse direction (CD), and the average value was calculated.

(2) Thickness (mm)

The thickness of five points on the four corners of the center of the basis weight measurement sample was measured, and an average value of 50 points was calculated. A thickness gauge having a load of 2 g / cm ² (load area: 4 cm ² ) was used.

(3) Bulk density (g / cm ³ )

The bulk density of the nonwoven fabric was determined by the following formula using the basis weight and thickness obtained in the above (1) and (2).

Bulk density = basis weight (g / m ² ) / (thickness (mm) / 10 × 100 × 100)

(4) Tensile strength (N / 50 mm) and elongation (%)

Measured according to JIS L 1906 (2010). A test piece of 300 mm (MD) x 50 mm (CD) was taken from the nonwoven fabric laminate for foam molding and was subjected to tensile testing using a tensile tester (Autograph AGS-J manufactured by Shimadzu Corporation) at a chuck distance of 200 mm and a head speed of 100 mm / 5 points and CD (direction orthogonal to the length): 5 points were measured, and an average value was calculated to obtain tensile strength and elongation, respectively.

(5) Air permeability (cm ³ / cm ² / sec)

A test piece of 200 mm (MD) x 50 mm (CD) was taken from the nonwoven fabric laminate for foam molding, and the flow rate at a pressure difference of 125 Pa was measured by a Prazier air permeability meter according to JIS L 1096 (2010).

(6) Moldability

20 cm square and 10 cm high was covered with a nonwoven fabric laminate for foam molding of 40 cm square (400 mm (MD) x 400 mm (CD)) and subjected to molding at 200 ° C by a vacuum pressure molding machine. The easiness of patterning at the molding process, the shape retention of the nonwoven fabric after processing, the dimensional stability, and the feeling (flexibility) were judged to be visual and tactile (feel touching hands) according to the following criteria.

AA: Processable and stiffening appearance and texture

A: Processable and usable as reinforcement

B: Processable but not as a reinforcing material

BB: can not be processed by melting etc.

(7) Thickness after heat pressing

The non-woven fabric of 10 cm square (100 mm (MD) x 100 mm (CD)) was subjected to a load of 5 kg and allowed to stand in an oven at 110 캜 for 5 minutes.

(8) Evaluation of urethane leaching

A 40 cm square (400 mm (MD) x 400 mm (CD)) nonwoven fabric laminate for foaming molding was placed in a fired pot to evaluate the uretane leaching visually according to the following criteria.

AA: Not verified

A: Almost never confirmed

B: Somewhat confirmed

BB: fairly confirmed

On the other hand, polyurethane was used as a resin material and foaming was carried out under the usual conditions of foamed polyurethane molding on the seat of an automobile, using an automobile seat sheet as a foaming pot.

[Example 1]

&Lt; Preparation of reinforcing layer &

Polyester short staple fiber mixture was formed into a nonwoven fabric sheet with a Prinzler punching machine to obtain a polyester staple fiber nonwoven fabric for a reinforcing layer. On the other hand, the polyester staple fiber mixture contains 30 mass% of the following PET3, 25 mass% of the following PET1, and 45 mass% of the following PET2.

PET 3: Core-sheath composite fiber of a low-melting-point polyester resin (PET copolymer) having a melting point of 110 ° C and a high-melting-point polyester resin (PET homopolymer) having a melting point of 250 ° C. &Quot; Melti 4080 &quot; manufactured by Unitika Co., Ltd., average fiber diameter 14 μm, average fiber length 51 mm.

PET1: A single fiber of a high-melting-point polyester resin having a melting point of 250 占 폚. Average fiber diameter 27 μm, average fiber length 64 mm.

PET2: A single fiber of a high-melting-point polyester resin having a melting point of 250 占 폚. Average fiber diameter 14 占 퐉, average fiber length 51 mm.

&Lt; Preparation of dense layer &

MFR is subjected to melt spinning at 230 ℃ using a propylene homopolymer minutes 60g / 10, it is deposited on the surface trapping the resultant filament, a basis weight of 6.0g / m ² of spun bond nonwoven fabric layer (S1) (fiber diameter 15μm) .

Next, a propylene homopolymer having an MFR of 400 g / 10 minutes was melted by an extruder at 280 DEG C, and the resulting melt was taken out from the spinneret and melt-blown at 280 DEG C (M) having a basis weight of 1.0 g / m &lt; ² &gt; by further depositing a spunbonded nonwoven fabric (S1) on the spunbonded nonwoven fabric (S1) And the three layers were integrated by a thermal embossing roll having an engraved area ratio of 18% to obtain a dense layer comprising SMS nonwoven fabric. The total basis weight of the dense layer was 13 g / m ² . On the other hand, &quot; PP-SMS &quot; described in Table 1 indicates SMS nonwoven fabric partially thermocompression-bonded. The &quot; laminated water &quot; is counted as one layer of the laminated material stacked in the order of SMS. The &quot; bulk density (per one layer) &quot; in the dense layer indicates the bulk density when one layer is stacked in the order of SMS.

&Lt; Production of nonwoven fabric laminate for foam molding &gt;

The dense layer and the reinforcing layer obtained by the above method were laminated and bonded together by a needle punch to obtain a nonwoven fabric laminate for foam molding. The properties of the resultant nonwoven fabric laminate for foam molding were measured by the above-described method. The results are shown in Table 1.

[Examples 2 to 6]

The basis weight, fiber diameter, and basis weight of the meltblown nonwoven fabric layer and the spunbond nonwoven fabric layer used for the dense layer of the polyester-based single-fiber nonwoven fabric used in the reinforcing layer were changed as shown in Table 1, To obtain a nonwoven fabric laminate for foam molding. The properties of the resultant nonwoven fabric laminate for foam molding were measured by the above-described method. The results are shown in Table 1.

[Comparative Examples 1 to 8]

The basis weight, fiber diameter, and basis weight of the meltblown nonwoven fabric layer and the spunbond nonwoven fabric layer used for the dense layer of the polyester-based single-fiber nonwoven fabric used in the reinforcing layer were changed as shown in Table 1, To obtain a nonwoven fabric laminate for foam molding. The dense layer was melted at the time of molding and the nonwoven fabric was made into a film, so that the urethane foam test could not be carried out. The results are shown in Table 1. On the other hand, in Table 1, &quot; - &quot;

On the other hand, the disclosure of Japanese application 2013-185735 is incorporated herein by reference in its entirety.

All publications, patent applications, and technical specifications described in this specification are herein incorporated by reference to the same extent as if each individual publication, patent application, and technical specification were specifically and individually indicated to be incorporated by reference .

Claims (23)

Wherein a reinforcing layer is laminated on at least one side of the dense layer,
Wherein the reinforcing layer contains 95% by mass to 50% by mass of thermoplastic resin short fibers having (A) 5% by mass to 50% by mass of thermoplastic resin fibers having a fiber diameter of 20 占 퐉 or more and (B) ) And the thermoplastic resin short fibers (B) are 100% by mass, and the thermoplastic resin short fibers of the above (A) or the thermoplastic resin short fibers of the above (B) (C) a composite polyester staple fiber comprising two or more kinds of resins having different melting points, wherein the content ratio of the composite polyester staple fibers (C) in the stiffening layer is 10% by mass to 40% by mass ,
Wherein the dense layer has a bulk density of the nonwoven fabric in the range of ^{0.05g / cm 3 ~0.3g / cm 3} ,
Wherein the dense layer and the reinforcing layer are entangled by needle punches. The method according to claim 1,
Wherein the foamed nonwoven fabric laminate has a thickness of 1.6 mm to 5.0 mm. The method according to claim 1,
Wherein the thickness of the nonwoven fabric laminate for foam molding after standing at 110 DEG C and 4.9 Pa for 5 minutes is 1.2 mm or more. The method according to claim 1,
At least a part of the composite polyester staple fibers of (C) has a fiber diameter of 20 탆 or less. The method according to claim 1,
Wherein the melting point of the at least one resin forming the composite polyester staple fibers of (C) is in the range of 110 to 190 캜. The method according to claim 1,
Wherein the dense layer comprises a nonwoven fabric obtained by partially thermocompression bonding, air through processing, resin bond processing or calendaring. The method according to claim 1,
Wherein the dense layer is a nonwoven fabric composed of long fibers. The method according to claim 1,
The thermoplastic resin staple fiber of (A) and the thermoplastic resin staple fiber of (B) are at least one kind of short fiber selected from the group consisting of polyester staple fibers and polyolefin staple fibers, . The method according to claim 1,
The thermoplastic resin short fibers of (A) and the thermoplastic resin short fibers of (B) are polyester short fibers. The method according to claim 1,
Wherein the dense layer comprises a long-fiber nonwoven fabric obtained by partially thermocompression bonding. The method according to claim 1,
Nonwoven laminate for the foam molding in the range of the basis weight of the dense layer ^{10g / m 2 ~35g / m 2} . The method according to claim 1,
Nonwoven laminate for the foam molding in the range of the air permeability of the dense layer ^{70cm 3 / cm 2 / sec~200cm 3} / cm 2 / sec. The method according to claim 1,
Wherein the dense layer is formed by laminating a spunbond nonwoven fabric layer (S) composed of long fibers on both sides of a meltblown nonwoven fabric layer (M) composed of long fibers, and the meltblown nonwoven fabric layer (M) And a spunbonded nonwoven fabric layer (S) partially thermocompression bonded to the spunbonded nonwoven fabric layer (S). The method according to claim 1,
Nonwoven laminate for the foam molding, the nonwoven fabric laminate for an air permeability with a pressure difference of 125Pa 25cm ³ / cm ² / sec~160cm of ³ / cm ² / sec foam molding. The method according to claim 1,
Nonwoven laminate for the basis weight of the nonwoven fabric laminate for the foam molding 20g / m ² ~160g / m ² of foam molding. The method according to claim 1,
Nonwoven laminate for the foam molding, the nonwoven fabric laminate for an air permeability with a pressure difference of 125Pa 25cm ³ / cm ² / sec~140cm of ³ / cm ² / sec foam molding. The method according to claim 1,
The basis weight of the reinforcing layer 40g / m ² non-woven fabric laminate for the foam molding in the range of ~150g / m ^2. A method for producing a nonwoven fabric laminate for foam molding according to any one of claims 1 to 17,
Wherein a reinforcing layer is laminated on at least one side of the dense layer and then the dense layer and the reinforcing layer are entangled by needle punches. 19. The method of claim 18,
After the spunbond nonwoven fabric layer (S) is laminated on both sides of the meltblown nonwoven fabric layer (M), partial thermocompression bonding, air through processing, resin bond processing or calendaring is performed to form the above- A method for producing a nonwoven fabric laminate for molding. An urethane foam molded article composite comprising a foamed urethane layer provided on the outer surface of a reinforcing layer of the nonwoven fabric laminate for foam molding according to any one of claims 1 to 17. 21. The method of claim 20,
Wherein the reinforcing layer and the foamed urethane layer are integrated to form a urethane foam molding. A urethane foamed molded article comprising the nonwoven fabric laminate for foam molding according to any one of claims 1 to 17 or a foamed urethane foam layer provided on the outer surface of the reinforcing layer of the nonwoven fabric laminate for foam molding And a composite. A urethane foamed molded article comprising the nonwoven fabric laminate for foam molding according to any one of claims 1 to 17 or a foamed urethane foam layer provided on the outer surface of the reinforcing layer of the nonwoven fabric laminate for foam molding Wherein the chair comprises a composite.